Breathing apparatus simulator

ABSTRACT

A breathing apparatus simulator unit (BASU) comprises a mouthpiece/noseclip subassembly and a cartridge subassembly. The mouthpiece/noseclip subassembly includes the same mouthpiece/noseclip subassembly that is utilized in an actual self-contained self-rescuer (SCSR) device. The cartridge subassembly comprises a container containing a reactionary material. The reactionary material reacts with at least one product of a user&#39;s exhalation to generate heat and resistance, thereby providing sensations to simulate the use of an actual SCSR.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 12/016,604,filed Jan. 18, 2008, and which claims the benefit of priority of U.S.Provisional Patent Application No. 60/885,821, filed Jan. 19, 2007, arehereby claimed, and the entire contents thereof are incorporated hereinby reference.

FIELD OF THE INVENTION

Present invention generally relates to breathing apparatus simulatorsand, more particularly, to breathing apparatus simulators for simulatingself-contained self-rescuer breathing apparatuses adapted for use insituations where temporary respiratory relief is desired.

BACKGROUND

Mining operations involving coal, iron ore, copper, and/or othermaterials include dangerous activities. These operations require minersto enter subterranean mines and perform various arduous miningactivities. Such subterranean mines have limited oxygen due to theirisolation from earth's outside atmosphere. Accordingly, one riskinvolved with such operations includes the potential for fires withinthe mine. Even a small fire can consume the limited oxygen supply withinthe mine and emit enough smoke to seriously harm the miners within themine whom may not be able to exit the mine fast enough.

One known means for alleviating such a risk includes the provision ofSelf-Contained Self-Rescuer (SCSR) devices within the mine. CommonSCSR's include closed-loop breathing apparatus comprising a mask, amouthpiece, and/or a nose-piece, an inlet fluidly coupled to a containercontaining a small amount of breathable air, i.e., oxygen, and an outletcoupled to a carbon dioxide scrubber. When donned by a miner, such knownSCSR's may provide the miner with breathable air for a fixed timeperiod, thereby allowing the miner to safely exit the mine to minimizerisk of suffocation due to smoke inhalation or lack of oxygen.

One concern arising with the use of SCSR's is that miners are notfamiliar with how the SCSR operates. More particularly, miners may notknow what to expect when donning and breathing with the SCSR. Forexample, as mentioned, typical SCSR's include closed-loop systemscomprising a breathing apparatus coupled to both a supply of breathableair and a carbon dioxide scrubbing device. The carbon dioxide scrubbingdevice tends to increase the temperature of the recycled breathable air.Therefore, during use, the sensation felt by the user may include a risein the temperature of the breathable air, as well as resistance to thenormal flow of breath. It is conceivable, for example, that a user whois not familiar with the SCSR may think that these sensations mean thatthe SCSR is malfunctioning. Alternatively, these sensations may cause auser to be frightened and panic. In either situation, the user may betempted to remove and discard the SCSR, thereby placing him or herselfin danger.

Accordingly, an important aspect of providing SCSR's within minesincludes training miners and other mine personnel on the properoperation and utilization of the SCSR's. The Mine Safety and HealthAdministration (MSHA) requires that each miner undergo annualexpectation training. However, it may not be cost-effective to performsuch training with the actual commercialized SCSR devices that areprovided in the mines. Therefore, the training allows for each miner toundergo annual training that includes breathing through a realisticSelf-Contained Self-Rescuer (SCSR) “training unit” that simulates thesensation of the breathing resistance and heat generated by an actualSCSR.

SUMMARY

One aspect of the present disclosure provides a breathing apparatussimulator unit (BASU) comprising a mouthpiece/noseclip subassembly and acartridge subassembly. In one form, the mouthpiece/noseclip subassemblyincludes the same mouthpiece/noseclip subassembly that is utilized in anactual Self-Contained Self-Rescuer (SCSR) device. The cartridgesubassembly comprises a container for containing a reactionary material.The reactionary material reacts with at least one product of a user'sexhalation to generate heat and resistance, thereby providing sensationsto simulate the use of an actual SCSR.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of one embodiment of a breathingapparatus simulator unit (BASU) constructed in accordance with theprinciples of the present invention;

FIG. 2 is a perspective view of the BASU of FIG. 1;

FIG. 3 is a bottom view of a mouthpiece component of the BASU of FIGS. 1and 2;

FIG. 4 is a perspective view of a cartridge subassembly of the BASU ofFIGS. 1 and 2;

FIG. 5 is a bottom view of the cartridge subassembly of the BASU of FIG.4;

FIG. 6 is a top view of the cartridge subassembly of the BASU of FIGS. 4and 5;

FIG. 7 is a front elevational view of a second embodiment of a BASUconstructed in accordance with the principles of the present disclosure;

FIG. 8 is a perspective view of the BASU of FIG. 7;

FIG. 9 is a partially cut-away perspective view of a cartridgesubassembly of the BASU of FIGS. 7 and 8;

FIG. 10 is a perspective view of a third embodiment of a BASUconstructed in accordance with the principles of the present disclosure;and

FIG. 11 is a perspective view of a fourth embodiment of a BASUconstructed in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION

FIGS. 1 and 2 depict one embodiment of a breathing apparatus simulatorunit (BASU) 10 constructed in accordance with the present invention. TheBASU 10 comprises a two-part open-circuit breathing apparatus assemblyincluding a mouthpiece/noseclip subassembly 12 and a cartridgesubassembly 14.

The mouthpiece/noseclip subassembly 12 comprises a mouthpiece 16 and anoseclip 18. In the disclosed embodiment, the mouthpiece 16 comprisesthe same mouthpiece as is utilized in actual commercialized versions ofthe Self-Contained Self-Rescuer (SCSR) devices. One advantage of usingthe same mouthpiece 16 as is used in the actual SCSR's is that the userof the BASU becomes familiar with the appearance and general feel of themouthpiece 16.

The mouthpiece 16 comprises a housing component 20, a conduit 22, a lipguard 24, and a pair of bite guards 26. Additionally, the mouthpiece 16is constructed to define a flow path that fluidly couples an opening 28in the lip guard 24 with the housing component 20, which contains thecartridge subassembly 14, via the conduit 22. Therefore, during use, auser positions the mouthpiece adjacent one's mouth and bites the biteguards 26 in a manner that is generally well known.

As depicted in FIG. 3, the housing component 20 has a generallyracetrack shaped cross-section (or top/bottom plan view) and defines anopening 30 for receiving the cartridge subassembly 14. In the disclosedembodiment, the opening 30 transitions into a truncated pyramid-shapedcavity within the housing component 20. Such cavity lends to anefficient flow of air through the mouthpiece 16. Moreover, the housingcomponent 20 comprises a pair of cleats 31, as depicted in FIGS. 1 and2. The cleats 31 are adapted to retain a tether or strap 33 formechanically connecting the noseclip 18 to the mouthpiece 16. In oneembodiment, the mouthpiece 16 is constructed of a material such as aplastic, rubber, or some similarly functional material.

The noseclip 18, as depicted in FIGS. 1 and 2, comprises a pair ofnosepads 32 and a spring 34. The spring 34 of the disclosed embodimentcomprises a torsion spring mechanically coupling the nosepads 32 andbiasing the nosepads 32 together. Accordingly, upon a user donning thenoseclip 18, the nosepads 32 compress the nostrils to seal the nasalcavity off from the atmosphere, thereby restricting any breathing to beperformed through the mouth.

The cartridge subassembly 14 comprises a double-barreled assemblyincluding a pair of canisters 36 and a coupler 38. As illustrated inFIG. 1, for example, the canisters 36 are hollow cylindrical canistershaving first open ends 36 a and second open ends 36 b. The first openends 36 a define openings that are in direct fluid communication withthe atmosphere. That is, the first open ends 36 a communicate with theatmosphere without interference, obstruction, or interruption from othercomponents of the device, or otherwise. The second open ends 36 b defineopenings in fluid communication with the coupler 38. So configured, thecanisters 36 define flow paths P extending from the atmosphere and themouthpiece 16 between the first and second open ends 36 a, 36 b, therebydefining an open-circuit breathing apparatus and enabling a user toinhale and exhale through the canisters 36. The canisters 36 aresubstantially completely filled with a reactionary material 40 (shown inFIG. 5, for example), which is retained therein with steel top andbottom screens 42 disposed adjacent the first and second open ends 36 a,36 b. FIG. 5 only depicts the bottom screens 42. FIG. 6 depicts the topscreens 42. The reactionary material 40, which will be described in moredetail below, enables the BASU 10 to provide sensations to the user thatsubstantially simulate the sensations experienced when using an actualSCSR.

Referring back to FIG. 4, the canisters 36 are constructed of paper,cardboard, chipboard, plastic, or any other material capable of servingthe principles of the present disclosure. For example, in oneembodiment, the canisters 36 are constructed of a material that servesas an insulator to retain heat during use of the BASU 10 to therebymaximize the efficiency at which the BASU 10 simulates an actual SCSR.The coupler 38 is constructed of plastic, for example, and comprises aring portion 38 a and a truss portion 38 b, as depicted in FIGS. 4 and6. The outside of the ring portion 38 a is sized and configured similarto the opening 30 in the housing component 20 of the mouthpiece 16 suchthat the coupler 38 may frictionally be retained therein. The trussportion 38 b extends across a mid-portion of the inside of the ringportion 38 a and, in combination with the ring portion 38 a, defines apair of circular openings 38 c (shown in FIG. 6) for receiving andretaining the canisters 36. In one embodiment, the canisters 36 arefrictionally retained within the coupler 38. In another embodiment, thecanisters 36 are retained within the coupler with an adhesive such asglue. Accordingly, the coupler 38 frictionally retains the canisters 36within the housing component 20 of the mouthpiece 16, as depicted inFIG. 2. Accordingly, with the cartridge subassembly 14 attached to themouthpiece 16, a user may use the BASU 10 during expectation training.

As mentioned above, the canisters 36 contain a reactionary material 40.In one embodiment, this reactionary material 40 is formulated such thatit provides both an increase in temperature of the breathing air andresistance to the flow of the breathing air through the BASU 10. In oneembodiment, the reactionary material 40 comprises a non-hazardous andnon-corrosive material that reacts exothermically with at least oneproduct of exhalation, i.e., H₂O, CO₂, O₂, etc. A non-hazardous materialis defined herein as a material that has not been assigned a UN or an NAnumber classifying it as a hazardous chemical and/or material.Preferably, the reactionary material 40 completely consists of anon-hazardous material that reacts exothermically with water vaporduring a user's exhalation. For example, during use, when a user exhalesthrough the reactionary material 40, a chemical reaction causes thereactionary material 40 to generate heat. Therefore, upon inhalation,the heat is picked up by the incoming ambient air to provide thesensation similar to that which would be provided by an actual SCSR,i.e., increased temperature of breathing air. Moreover, because thereactionary material 40 at least partly obstructs the flow path of thebreathing, it generates resistance, which also simulates the performanceof the actual SCSR.

In one embodiment, the reactionary material 40 completely comprises amolecular sieve desiccant having a 4×8 mesh bead size, which iscommercially available from Delta Adsorbents, Division of DeltaEnterprises, Inc., of Roselle, Ill., USA. Such a molecular sievedesiccant includes a 4 angstrom nominal pore diameter, a 24% wt.theoretical equilibrium water capacity, 1.5% wt. water content, 1800BTU/lb H2O maximum heat of adsorption, approximately 0.23 BTU/lb/deg Fspecific heat, 18 lbs crush strength, and 2.5-4.5 millimeter nominalcommercial bead size. In alternative embodiments, the reactionarymaterial 40 could at least partly comprise other materials such aslithium hydroxide, soda lime, or any other material capable of servingthe principles of the present invention. Also, while a molecular sievedesiccant having a 4×8 mesh bead size has been disclosed, other meshbead sizes can be used. For example, smaller mesh sizes can providegreater breathing resistance, and greater mesh size can provide lessbreathing resistance. Accordingly, the particular operatingcharacteristics of the resistance can potentially be changed to simulatedifferent breathing conditions or apparatuses.

While the BASU 10 has been described thus far as comprising adouble-barreled cartridge subassembly 14, alternative embodiments maycomprise other configurations. For example, FIGS. 7 and 8 depict oneembodiment of the BASU 10 comprising a mouthpiece/nosepiece subassembly12 identical to that disclosed with reference to FIGS. 1 and 2, but withan alternative cartridge subassembly 114. Specifically, the cartridgesubassembly 114 depicted in FIGS. 7 and 8 comprises a single canister136 shaped with a racetrack cross-section, similar to the opening 30(shown in FIG. 3) in the mouthpiece 16. So configured, the canister 136of the cartridge subassembly 114 may not require a coupler componentsimilar to the coupler 38 described above. Rather, the canister 136 maydirectly frictionally engage with the opening 30 in the mouthpiece 16.Otherwise the cartridge subassembly 114 depicted in FIGS. 7 and 8 isconstructed identical to the cartridge subassembly 14 depicted in FIGS.1 and 2 and described above. For example, as shown in FIG. 9, thecanister 136 includes a generally hollow canister for containing thereactionary material 40 (not shown) and a pair of steel screens 142 forretaining the reactionary material 40 in the canister 136. Moreover, asdepicted, the outside surface of the canister 136 includes a bead 146extending around a top portion thereof. The bead 146 aids in thefrictional engagement between the canister 136 and the mouthpiece 16adjacent the opening 30. The canister 136 may be constructed of any ofthe materials discussed above with respect to the canisters 36. In aplastic embodiment of the canister 136, the canister may be constructedthrough an extrusion process.

In light of the foregoing, it should be appreciated that the cartridgesubassembly 14, 114 need not take any specific shape or form, butrather, may be designed as desired. For example, while the cartridgesubassembly 14 depicted in FIGS. 1 and 2 includes a pair of generallycylindrical canisters 36, and the cartridge subassembly 114 depicted inFIGS. 7 and 8 includes a generally racetrack shaped canister 136,alternative embodiments can take any shape and configuration. Forexample, FIG. 10 illustrates a cartridge subassembly 214 including asingle cylindrical canister 236 co-molded with a pair of conduitportions 238. The pair of conduit portions 238 may therefore attach tothe mouthpiece 16 via a coupler (not shown), which is similar to thecoupler 38 disclosed and described above with reference to FIGS. 4 and6. Moreover, FIG. 11 depicts another alternative embodiment of acartridge subassembly 314 comprising a single frustoconically-shapedcanister 336 co-molded with first and second conduit portions 338 a, 338b. The first conduit portion 338 a is coupled directly with the canister336 and in fluid communication between the canister 336 and themouthpiece 16. The second conduit portion 338 b is disposed beside thefirst conduit portion 338 a and may be adapted to be closed, or toreceive a valve, or some other apparatus for some other use.Nevertheless, it should be appreciated that the shape and configurationof the cartridge subassemblies 14, 114, 214, 314 may be varied, asdesired for any particular use. In any such configuration, the cartridgesubassembly 14, 114, 214, 314 still contains the reactionary material40. Furthermore, each of the canisters 236, 336, of the subassemblies214, 314, respectively, comprise at least co-molded screens (illustratedon the bottom side thereof) and potentially co-molded top-screens (notshown) instead of the steel screens discussed above with canisters 36and 136.

Furthermore, while the cartridge subassemblies 14, 114, 214, 314 havebeen disclosed herein as being used with the mouthpiece 16 particularlydepicted and described, it should be appreciated that the cartridgesubassemblies 14, 114, 214, 314 may be adapted to be used with anydesign of mouthpiece subassembly. The scope of the present invention,and thus, this disclosure is not limited to the particular mouthpiecesubassembly disclosed herein. In this regard, the cartridge subassembly14, 114, 214, 314 may be offered without the mouthpiece subassembly andalternatively, with an adapter component that serves to mechanicallyadapt the cartridge subassembly 14, 114, 214, 314 to differentmouthpiece subassemblies available on the market.

Further still, in a preferred embodiment, the BASU 10 constructed inaccordance with the principles of the present invention can further beequipped with a filter (not shown) disposed between the top screen 42(FIG. 6) and the mouthpiece 16. The filter can serve to capture nuisancedust that can accumulate within the cartridge subassembly 14, 114, 214,314, for example, such that a user does not inhale the same. In oneembodiment, the filter can comprise a permanently charged electrostaticpolypropylene web situated immediately adjacent the top screen 42. Suchfilters typically have higher efficiencies with lower pressure dropcompared to purely mechanical filter media. Nevertheless, alternativeembodiments of the BASU 10 can include filters of different materialssuch as those constructed of fiberglass, for example, or no filter atall.

In light of the foregoing, it should be appreciated that a breathingapparatus simulator constructed in accordance with the embodimentsdisclosed herein provides a cost-effective simulator that allows foreasy replacement and disposal of spent cartridge subassemblies 14.Specifically, after a user uses a cartridge subassembly 14 during atraining operation, the spent cartridge subassembly 14 can simply beremoved from the mouthpiece 16 and replaced with a new cartridgesubassembly 14.

Additionally, when using the preferred embodiment of the spent cartridgesubassembly 14, which includes only non-hazardous reactionary material40, the spent cartridge subassembly 14 can be discarded into a standardtrash can. When the cartridge subassembly 14 includes hazardousreactionary material 40, the cartridge subassembly 14 must be discardedin accordance with disposal standards for hazardous waste.

Other advantages realized in using only non-hazardous reactionarymaterial 40 are that the user of the breathing apparatus simulator unit10 is absolutely free from inhaling hazardous and/or corrosive gasesand/or dusts. Further, shipping and manufacturing costs associated withnon-hazardous materials are generally less than those costs associatedwith hazardous material.

Finally, it should be appreciated that the various embodiments describedherein are merely examples of what the inventor considers the invention,which is defined by the spirit and scope of the following claims.

What is claimed:
 1. A breathing apparatus, comprising: a mouthpiece; acanister removably attached to the mouthpiece, the canister defining afirst opening in direct fluid communication with the atmosphere, asecond opening in fluid communication with the mouthpiece, and aflowpath extending between the first and second openings, the flow pathproviding fluid communication between the mouthpiece and the atmosphere;and a porous material substantially completely filling the canister andfor reacting with at least one product of a user's exhalation togenerate heat and resistance, thereby providing sensations to the userthat simulate the use of an actual self-contained self-rescuer device,the porous material consisting of a non-hazardous material.
 2. Theapparatus of claim 1, wherein the porous material comprises a pluralityof beads.
 3. The apparatus of claim 1, wherein the porous materialcomprises a molecular sieve dessicant.
 4. The apparatus of claim 1,wherein the porous material comprises a nominal pore diameter ofapproximately 4 angstrom.
 5. The apparatus of claim 1, wherein theporous material comprises a maximum heat of adsorption of 1800 BTU/lbH2O.
 6. The apparatus of claim 1, wherein the porous material reactsexothermically with H2O.
 7. The apparatus of claim 1, further comprisinga mesh material retaining the porous material within the container. 8.The apparatus of claim 7, wherein the mesh material comprises a steelmesh material.
 9. The apparatus of claim 1, wherein the canister isconstructed of a thermally insulating material.
 10. The apparatus ofclaim 9, wherein the canister is constructed of one of a plasticmaterial, a paper material, a cardboard material, and a chipboardmaterial.
 11. A breathing apparatus, comprising: a mouthpiece; acanister removably attached to the mouthpiece, the canister providingfluid communication between the atmosphere and the mouthpiece; and anon-hazardous means for generating heat and resistance in response to auser's exhalation to simulate the use of an actual self-containedself-rescuer device, the non-hazardous means being porous andsubstantially completely filling the canister.
 12. The apparatus ofclaim 11, wherein the non-hazardous means comprises a plurality ofbeads.
 13. The apparatus of claim 11, wherein the non-hazardous meanscomprises a molecular sieve dessicant.
 14. The apparatus of claim 11,wherein the non-hazardous means comprises a nominal pore diameter ofapproximately 4 angstrom.
 15. The apparatus of claim 11, wherein thenon-hazardous means comprises a maximum heat of adsorption of 1800BTU/lb H2O.
 16. The apparatus of claim 11, wherein the non-hazardousmeans reacts exothermically with H2O.
 17. The apparatus of claim 11,further comprising a mesh material retaining the non-hazardous meanswithin the canister.
 18. The apparatus of claim 17, wherein the meshmaterial comprises a steel mesh material.
 19. The apparatus of claim 11,wherein the canister is constructed of a thermally insulating material.20. The apparatus of claim 11, wherein the canister is constructed ofone of a plastic material, a paper material, a cardboard material, and achipboard material.